Additive manufacturing apparatus, system and method

ABSTRACT

A system and method for providing centrifuge-based additive object manufacturing includes a rotating drum containing a photopolymer material that solidifies when irradiated by a light source, the photopolymer material spreads evenly over an item being manufactured when the rotating drum is in motion, a light source module emitting a light capable of solidifying the photopolymer material, a set of platform actuator elements coupled to a plurality of perforated platforms for controlling a position of the plurality of perforated platforms within the rotating drum while in operation, and a photopolymer material delivery system for adding a controlled amount of the photopolymer material into the rotating drum. The light source module moves inside the rotating drum and selectively emits its light solidifying the part of the layer above the plurality of perforated platforms in the areas crossing the object currently being manufactured.

TECHNICAL FIELD

This application relates in general to a system and method for providing3D object manufacturing, and more specifically, to a system and methodfor providing centrifuge-based additive object manufacturing.

BACKGROUND

Current techniques for additive manufacturing of three-dimensionalobjects (e.g., stereolithography, 3-D printing, etc.) can produceexcellent quality products with high fidelity, but such techniques havesignificant limitations. Typically, such techniques work in one of threeways: (a) continually polymerizing layers at or near the surface ofliquid resin contained in a stationary vat, (b) continually polymerizinglayers of resin at or near the bottom of a stationary vat of resinthrough a transparent membrane, or (c) continually polymerizing layersof resin that have been jetted downward by one or more single-nozzle ormulti-nozzle print heads.

Technique (a) requires maintaining tight control over the material leveland leading to part inaccuracies due to a meniscus forming, voids duringmaterial application, etc. Technique (b) often causes process failuresand thus destruction of the objects forming due to separation forces.Even utilizing the so-called “dead zone” is prone to failures due tovacuum forces created during the process of delivering material for thenext layer. Technique (c) requires a uniform distribution of a newlyformed layer over the previous one, which is not an easy task.

Therefore, a need exists for a system and method for providingcentrifuge-based additive object manufacturing. The present inventionattempts to address the limitations and deficiencies of prior solutionsutilizing the principles and example embodiments as disclosed herein.

SUMMARY

In accordance with the present invention, the above and other problemsare solved by providing a system and method for providingcentrifuge-based additive object manufacturing according to theprinciples and example embodiments disclosed herein.

In one embodiment, the present invention is a system for providingcentrifuge-based additive object manufacturing. The system providingcentrifuge-based additive object manufacturing includes a rotating drumcontaining a photopolymer material that solidifies when irradiated by alight source, the photopolymer material spreads evenly over an itembeing manufactured when the rotating drum is in motion, a light sourcemodule emitting a light capable of solidifying the photopolymermaterial, a set of platform actuator elements coupled to a plurality ofperforated platforms for controlling a position of the plurality ofperforated platforms within the rotating drum while in operation, and aphotopolymer material delivery system for adding a controlled amount ofthe photopolymer material into the rotating drum. The light sourcemodule moves inside the rotating drum and selectively emits its lightsolidifying the part of the layer above the plurality of perforatedplatforms in the areas crossing the object currently being manufactured.

In another aspect of the present invention, the photopolymer materialdelivery system adds additional photopolymer material to the rotatingdrum after the light source module solidifies a new layer onto the itembeing manufactured before the light source module activates to solidifya next layer.

In another aspect of the present invention, air pressure within therotating drum is raised above surrounding atmospheric air pressure whilethe rotating drum is in operation.

In another aspect of the present invention, centrifugal force exertedonto the photopolymer material within the rotating drum is raised abovesurrounding gravity while the rotating drum is in operation.

In another aspect of the present invention, the photopolymer materialdelivery system comprises a material delivery module inserted within therotating drum on an opposing side from the light source module.

In another aspect of the present invention, the photopolymer materialdelivery system comprises a set of material delivery nozzles located ona bottom surface within the rotating drum on an opposing side from thelight source module.

In another embodiment of the present invention is a system for providingpressure-based additive object manufacturing. The system includes apressure vessel containing a photopolymer material that solidifies whenirradiated by a light source, the photopolymer material spreads evenlyover an item being manufactured when the rotating drum is in motion, thepressure vessel having a transparent top surface, a light source moduleemitting a light capable of solidifying a top layer of the photopolymermaterial through the transparent top surface of the pressure vessel, aplatform actuator coupled to a movable platform for controlling avertical position of the movable platform within the pressure vesselwhile in operation, the platform actuator moves to position a currenttop surface the item being manufactured a single layer below a currentlevel of the photopolymer material, and a photopolymer material deliverysystem for adding a controlled amount of the photopolymer material intothe pressure vessel. The light source module selectively emits its lightsolidifying the single layer below a current level of the photopolymermaterial above the object currently being manufactured.

In another aspect of the present invention, the light source moduleemits a different light pattern for each layer of the item beingmanufactured to solidify the photopolymer material according to thedifferent light pattern.

In another aspect of the present invention, the system further comprisesa photopolymer material delivery system for adding a controlled amountof the photopolymer material into the pressure vessel.

In another embodiment, the present invention is a method for providingcentrifuge-based additive object manufacturing. The method rotates adrum having set of platform actuator elements coupled to a plurality ofperforated platforms for controlling a position of the plurality ofperforated platforms within the rotating drum, inserts a controlledamount of photopolymer material into the rotating drum, selectivelysolidifies a layer of the photopolymer material onto an item beingmanufactured using a light source module emitting its light onto thelayer of the photopolymer material, and adjusting a position of thelight source module to a new position to solidify a next layer of thephotopolymer material.

In another aspect of the present invention, the method further comprisesadding additional photopolymer material to the rotating drum beforesolidifying the next layer.

The foregoing has outlined rather broadly the features and technicaladvantages of the present invention in order that the detaileddescription of the invention that follows may be better understood.Additional features and advantages of the invention will be describedhereinafter that form the subject of the claims of the invention.

It should be appreciated by those skilled in the art that the conceptionand specific embodiment disclosed may be readily utilized as a basis formodifying or designing other structures for carrying out the samepurposes of the present invention. It should also be realized by thoseskilled in the art that such equivalent constructions do not depart fromthe spirit and scope of the invention as set forth in the appendedclaims. The novel features that are believed to be characteristic of theinvention, both as to its organization and method of operation, togetherwith further objects and advantages will be better understood from thefollowing description when considered in connection with theaccompanying figures. It is to be expressly understood, however, thateach of the figures is provided for the purpose of illustration anddescription only and is not intended as a definition of the limits ofthe present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the drawings in which like reference numbers representcorresponding parts throughout:

FIGS. 1a-e illustrate a first embodiment for a system that providescentrifuge-based additive object manufacturing according to the presentinvention;

FIG. 2 illustrates components within the first embodiment for a systemthat provides centrifuge-based additive object manufacturing accordingto the present invention;

FIGS. 3a-d illustrate a second embodiment for a system that providescentrifuge-based additive object manufacturing according to the presentinvention;

FIGS. 4a-d illustrate a third embodiment for a system that providescentrifuge-based additive object manufacturing according to the presentinvention;

FIGS. 5a-d illustrate a fourth embodiment for a system that providescentrifuge-based additive object manufacturing according to the presentinvention;

FIGS. 6a-b illustrate a pair of embodiments for a system that providespressure chamber-based additive object manufacturing according to thepresent invention;

FIG. 7 illustrates a method and algorithm for providing acentrifuge-based additive object manufacturing according to the presentinvention;

FIG. 8 illustrates software components within an example embodiment fora computer-based control system utilized within centrifuge-basedadditive object manufacturing according to the present invention; and

FIG. 9 illustrates a generalized schematic of a programmable processingsystem utilized as the various computing components described hereinused to implement an embodiment of the present invention.

DETAILED DESCRIPTION

This application relates in general to a system and method for providing3D object manufacturing, and more specifically, to a system and methodfor providing centrifuge-based additive object manufacturing accordingto the present invention.

Various embodiments of the present invention will be described in detailwith reference to the drawings, wherein like reference numeralsrepresent like parts and assemblies throughout the several views.Reference to various embodiments does not limit the scope of theinvention, which is limited only by the scope of the claims attachedhereto. Additionally, any examples set forth in this specification arenot intended to be limiting and merely set forth some of the manypossible embodiments for the claimed invention.

In describing embodiments of the present invention, the followingterminology will be used. The singular forms “a,” “an,” and “the”include plural referents unless the context clearly dictates otherwise.Thus, for example, reference to “a needle” includes reference to one ormore of such needles and “etching” includes one or more of such steps.As used herein, a plurality of items, structural elements, compositionalelements, and/or materials may be presented in a common list forconvenience. However, these lists should be construed as though eachmember of the list is individually identified as a separate and uniquemember. Thus, no individual member of such list should be construed as ade facto equivalent of any other member of the same list solely based ontheir presentation in a common group without indications to thecontrary. As used herein, the singular forms “a,” “an,” and “the” areintended to include the plural forms as well, unless the context clearlyindicates otherwise.

It further will be understood that the terms “comprises,” “comprising,”“includes,” and “including” specify the presence of stated features,steps or components, but do not preclude the presence or addition of oneor more other features, steps or components. It also should be notedthat in some alternative implementations, the functions and acts notedmay occur out of the order noted in the figures. For example, twofigures shown in succession may in fact be executed substantiallyconcurrently or may sometimes be executed in the reverse order,depending upon the functionality and acts involved.

As used herein, the term “about” means that dimensions, sizes,formulations, parameters, shapes, and other quantities andcharacteristics are not and need not be exact, but may be approximatedand/or larger or smaller, as desired, reflecting tolerances, conversionfactors, rounding off, measurement error and the like, and other factorsknown to those of skill. Further, unless otherwise stated, the term“about” shall expressly include “exactly.”

The terms “worker” and “user” refer to an entity, e.g. a human, usingthe centrifuge-based additive object manufacturing system including anysoftware or smart device application(s) associated with the invention.The term user herein refers to one or more users.

The term “connection” refers to connecting any component as definedbelow by any means, including but not limited to, a wired connection(s)using any type of wire or cable for example, including but not limitedto, coaxial cable(s), fiberoptic cable(s), and ethernet cable(s) orwireless connection(s) using any type of frequency/frequencies or radiowave(s). Some examples are included below in this application.

The term “invention” or “present invention” refers to the inventionbeing applied for via the patent application with the title “ACentrifuge-based Additive Object Manufacturing Apparatus, System andMethod.” Invention may be used interchangeably with device.

In general, the present disclosure relates a system and method forproviding 3D object manufacturing. To better understand the presentinvention, FIGS. 1a-d illustrate a first embodiment for a system thatprovides centrifuge-based additive object manufacturing according to thepresent invention. An apparatus for producing a three-dimensionalobject(s) shown in FIGS. 1a-d includes at least one of: a drum capableof rotating around its axis, a material delivery system, anelectromagnetic wave source (light, IR or UV), and a build platform.This apparatus' 3D object manufacturing system 100 utilizes a method ofapplying a new layer of material, such as a photopolymer, a powder orany other type of material that is changing phase or solidifying underirradiation. This apparatus 100 resolves known problems with existingmethods of a material applications using vacuum or capillary blade,drums, curtain coating, membranes, and the like.

FIG. 1a shows a rotating drum 101 having a plurality of perforatedplatforms 102 a-c positioned within the rotating drum 101, a lightsource module 103, and a set of platform actuator elements 104 a-ccoupled to a plurality of perforated platforms 102 a-c that control theposition of the plurality of perforated platforms 102 a-c within therotating drum 101 while in operation.

At the beginning the perforated platform is oriented in its mostadvanced position. The plurality of perforated platforms 102 a-c couldbe solid platforms in place of perforated ones. The rotating drum 101 isinitially filled with a given amount of material 105. The light sourcemodule 103 is positioned outside the rotating drum 101.

When the rotating drum 101 starts spinning, the material 105 within therotating drum 101 spreads evenly over the plurality of perforatedplatforms 102 a-c in a single layer thickness. The light source module103 moves inside the rotating drum 101 and starts selectively emittingits light, thus solidifying the part of the layer above the plurality ofperforated platforms 102 a-c in the areas crossing the object currentlybeing manufactured. Once complete, the plurality of perforated platforms102 a-c are moved one layer outward causing the material 105 to spreadevenly over the newly formed section and the process repeats.

FIG. 1b shows the rotating drum 101 at an initial position while atrest. The rotating drum 101 is locked into a fixed position and material105 is added to the rotating drum 101. The added material 105 fills therotating drum 101 to the material level 107. The light source module 103includes a set of level sensors 106 to provide material 105 measurementswhen the light source module 103 is in the rotating drum 101.

FIG. 1c shows the rotating drum 101 and the material 105 when therotating drum 101 is rotating at a high RPM and the material 105 hasbeen evenly spread about the plurality of perforated platforms 102 a-c.The light source module 103 is lowered into the rotating drum 101 andthe level sensors 106 provide measurements of the material level 107.FIG. 1c shows the condition of the apparatus 100 before the light sourcemodule 103 irradiates any of the material 105. The light source module103 then selectively irradiates the material 105 while the rotating drum101 spins and the process repeats until the part 109 is built.

FIG. 1d shows the part built 109 within the rotating drum 101 as it ispositioned in front of the plurality of perforated platforms 102 a-c.Once the part built 109 reaches its final configuration, the lightsource module 103 may be removed from within the rotating drum 101, therotating drum 101 may stop spinning, and the part built 109 may beremoved for cleaning and final processing.

In the above examples of the first embodiment, the light source module103 is made of multiple emitters, primarily solid state lasers; althougha single emitter may also be used. Accuracy of each emitter toilluminate a particular location on the part built 109 while therotating drum 101 is in motion may be controlled by switching eachemitter on/off while the particular emitter is directed at a desiredlocation on the part built 109. The location on the part built 109 maybe determine in a vertical axis from the position of a particularemitter in the array of light source module 103 and the known depth ofthe light source module when it is lowered into the rotating drum 101.The horizontal resolution of the location in which the emitter isdirected may be determined using a ratio between the vertical speed ofthe laser vs RPM of the drum determines the vertical resolution.

A close analogue to the operation of the light source module 103 as theemitters solidifies material 105 onto a part built would be a lathecutting the thread on the cylinder. With the same advance speed, Ahigher RPM of the lathe results in a tighter the neighboring threads. Incase of plural emitters, each of them is covering its own portion of themodel in vertical direction. Everything should be synchronized. Amountof material delivered per second (or the platform speed in case ofmoving platform) determines the speed of the printing in the inwarddirection, RPM of the drum combined with the speed of the emitterscontrols resolution in up/down direction (“threads” per mm) and themodulating frequency of each emitter determines horizontal resolution.

FIG. 1e shows various effects of pressure involved in depositingmaterial evenly for manufacture. One of the biggest problem in additive3D printing is a deposition of thin even layers of material, such aspowder, photometer, solutions etc., prior to the selectivesolidification as described above. Spreading material with any kind ofmechanical spreaders such as blade, roller depositor, coating etc.causing problems such us meniscus, voids in the part area, dangeroushills and other local thickness deviations.

The present invention utilizes a pair of innovative material depositionprinciples. Both of these principles allow the material to be uniformlydeposited onto an object as it is manufactured without mechanicalcontact with the part forming area. High pressure 142 as compared toatmospheric pressure 141 or high gravity forces 144 as compared toEarth's 1 G gravity are responsible for material to be delivered anevenly distributed over newly formed layer forming even layer ofmaterial of the given thickness. FIG. 1e illustrates effect of the highpressure 142 and high gravity forces 144 shown to increase the contactangle(s) 146-147 and overcome low wetting and surface tension found inmost depositing processes. These principles are included within thepresent invention as disclosed below in reference to FIG. 6a -b.

FIG. 2 illustrates components within the first embodiment of a systemthat provides centrifuge-based additive object manufacturing accordingto the present invention. The use of a centrifuge 100 uses a higherlevel of gravitational force from the rotating motion of the centrifuge100 utilizes to force the layer of added material to spread evenlyacross the object being fabricated as the chamber and materials spins.

FIGS. 3a-d illustrate a second embodiment of a system that providescentrifuge-based additive object manufacturing according to the presentinvention. FIG. 3a shows the rotating drum 101, the light source module103, and a material depositation module 111 that work together in thisembodiment. The rotating drum 101 initially is empty and the lightsource module 103 is outside the rotating drum 101 in a still positionof FIG. 3 b. The material depositation module 111 (MDM) is loweredinside the rotating drum 101 in the initial position of FIG. 3c until itis almost touching the inner surface of the rotating drum 101.

When the rotating drum 101 starts spinning at full speed as seen in FIG.3 d, the material depositation module 111 starts depositing material105. Due to centrifugal forces, material 105 spreads evenly covering aplurality of perforated platforms 102 a-c by a single layer thickness,then depositation stops.

The light source module 103 moves downward inside the rotating drum 101and then horizontally toward the inner surface of the rotating drumrotating drum 101. The light source module 103 stops on a focal line 108from the newly formed layer of material 105. The light source module 103starts selectively emitting, solidifying the part of the layer above theplurality of perforated platforms 102 a-c in the areas crossing theobject currently being manufactured.

The light source module 103 and material depositation module 111 aremoving one layer inward, the material depositation module 111 depositsenough material to create a new layer of material 105 over the newlyformed section and the process repeats until the part 109 is complete.The focal lines 108 and the level sensors 106 operate ??? in thisembodiment.

FIGS. 4a-d illustrate a third embodiment for a system that providescentrifuge-based additive object manufacturing according to the presentinvention. In this embodiment, the rotating drum 101 is initially emptyas shown in FIG. 4 a. The material supply compartment 121 containsenough material 105 to complete the build.

The light source module 103 begins outside the rotating drum 101 asshown in FIG. 4 b. The rotating drum 101 starts spinning in FIG. 4c anda portion of the material 105 is forced by centrifugal forces to thesupply compartment 121, pushed through the multiple nozzles 124 into therotating drum 101 and evenly covering the perforated inner wall 122 ofthe rotating drum 101 in a single layer thickness.

The light source module 103 moves downward inside the 101 and thenhorizontally toward the perforated inner wall 122 of the rotating drum101 stopping on the focal distance focal lines 108 from the newly formedlayer. The light source module 103 starts selectively emitting,solidifying the part of the layer above the plurality of perforatedplatforms 102 a-c in the areas crossing the object currently beingmanufactured.

The light source module 103 moves one layer inward; multiple nozzles 124open to deposit enough material 105 to create a new layer over a newlyformed section and the process repeats. The light source module 103 ofthe third embodiment is the same as in the previous embodimentsdisclosed above. The difference between these embodiments us found inthe way material 105 is being supplied. The material 105 is eithercoming from the bottom compartment through the nozzles or being suppliedto the bottom of the drum during the build and then high g-forces movematerial upwards to the part forming area.

FIGS. 5a-d illustrate a fourth embodiment of a system that providescentrifuge-based additive object manufacturing according to the presentinvention. The rotating drum 101 is initially empty and the materialsupply compartment 121 is empty in the initial state of FIG. 5 a. Thelight source module 103 is outside the rotating drum 101.

The rotating drum 101 starts spinning as shown in FIG. 5 c. An amount ofmaterial needed to create just one layer is deposited into the supplycompartment 121. Due to centrifugal forces, a portion of the material105 from the supply compartment 122 is pushed through the nozzles 124into the 101 and spreads evenly over a perforated inner wall 122 of therotating drum 101 by a single layer thickness.

The light source module 103 moves downward inside the rotating drum 101and then horizontally toward the perforated inner wall 122, 101 stoppingon the focal distance 108 lines of the newly formed layer. The lightsource module 103 starts selectively emitting, solidifying the part ofthe layer above the platform in the areas crossing the object currentlybeing manufactured.

The light source module 103 moves one layer inward, a new portion ofmaterial is pumped into the supply compartment 122 and then into 101 thedrum; enough material is provided to create a new layer over the newlyformed section of the part built 109 as the multiple nozzles 124 stayopen all the time and the process repeats.

FIGS. 6a-b illustrate a pair of embodiments for a system that providespressure chamber-based additive object manufacturing according to thepresent invention. FIG. 6a shows a first embodiment of a pressure-basedmaterial delivery and fabrication system according to the presentinvention. A pressure vessel 601 is utilized to form a 3D model 650within the vessel 601.

The pressure vessel 601 includes a sealed lid 603 containing atransparent glass insert 604 to create an internal pressure chamber 601a in which a 3D model is being formed. The upper portion of the chamber601 a is pressurized using a pressure inlet 604 located near the lid603. Material 601 b used to create the 3D model enters the pressurechamber 601 a from a delivery port 606 located on the bottom of thepressure vessel 601. Pressure within the upper portion of the pressurechamber 601 a forces the material 601 b to remain in a lower portion ofthe pressure chamber 601 a.

A light source module (LSM) 610 is positioned above the transparentsurface 604 in the lid 603 in which the LSM 610 focuses a light patternat a focal distance 611 from the top of the material 601 b. As withother embodiments, the LSM 610 solidifies the material 601 b atparticular locations on the top surface of the material 601 b. Using amask to the light source within the LSM 610, the material 601 b may besolidified at specific locations along the top of the material 601 b.The LSM 610 may move up and down as needed to alter the size and focusof the image projected onto the material 601 b.

Using this configuration, a 3D model 650 begins as only one thin layerof material covering a platform 605 at the bottom of the pressurechamber 601 a. The LSM 610 selectively cures this surface through theglass on the top of the pressure chamber 601 a. As soon as a currentlayer is partially solidified, a calculated amount of new material 601 bis being injected into the pressure chamber 601 a thus forming a newlayer of material 601 b above the newly formed one.

Due to the high pressure inside the pressure chamber 601 a, the newlydeposited material 601 b spreads evenly without any meniscus, hills orvoids across the 3D model 650 being formed within the pressure chamber601 a. The LSM 610 moves up the distance equal to the thickness of thenewly formed layer to maintain its position at the focal distance 611above the top of the material 601 b. The process repeats until theentire 3D model 650 is formed within the pressure chamber 601 a. Thepressure within the pressure chamber 601 a may be reduced to allow thelid 603 to be removed and the 3D model 610 may be taken from thepressure vessel 601 for finishing. Any remaining unused material 601 bmay be removed and a new 3D model 650 may be fabricated as describedabove.

FIG. 6b shows a second embodiment of a pressure-based material deliveryand fabrication system according to the present invention. The pressurevessel 601 is utilized to form a 3D model 650 within the vessel 601 in asimilar process disclosed above with a few modification. The pressurevessel 601, the lid, the transparent glass insert 604, the pressureinlet 604, and LSM 610 are present in this embodiment. The platform 605is located on a plunger 607 that can travel up and down raising andlowering the 3D model 650 within the material 601 b. The pressure withinthe pressure chamber 601 a maintains the material 601 b in the bottom ofthe pressure vessel 601 as above.

However, instead of injecting new material 601 b into the pressurevessel 601, the plunger 607 moved the platform 605 up and down to keepthe top surface of the 3D model 650 located just below the surface ofthe material 601 b. The LSM 610 is moved accordingly to maintain thefocal distance 611 as needed.

At the beginning of the process, the platform 605 located in an UPposition, one layer below the material 601 b surface. The LSM 610selectively cures this surface through the glass 604 within the lid 603of the pressure vessel 601. As soon as current layer is partiallysolidified, the plunger 607 moves platform 605 one layer down. The 3Dmodel 650 being formed is pulled into the unsolidified material 601 b.Due to the high pressure inside the pressure chamber 601 a, the material601 b spreads evenly without any meniscus, hills or voids across the topof the 3D model 605. The process repeats until the entire 3D model isformed.

Once again, pressure within the pressure chamber 601 a may be reduced toallow the lid 603 to be removed and the 3D model 610 may be taken fromthe pressure vessel 601 for finishing. Any additional material 601 bneeded to fabricate another 3D model may be added, the platform 605 onceagain raised to the UP position, and a new 3D model 650 may befabricated as described above.

FIG. 7 illustrates a method and algorithm for providing acentrifuge-based additive object manufacturing according to the presentinvention. The process 700 begins 701, and in step 711, a drum havingset of platform actuator elements coupled to a plurality of perforatedplatforms for controlling a position of the plurality of perforated isrotated. Next, a controlled amount of photopolymer material is insertedin step 712 into the rotating drum.

A a layer of the photopolymer material is selectively solidified onto anitem being manufactured using a light source module emitting its lightonto the layer of the photopolymer material in step 713. Next in step714, a position of the light source module is adjusted to a new positionto solidify a next layer of the photopolymer material.

Process 700 ends 702 after step 715 adds additional photopolymermaterial to the rotating drum before solidifying the next layer.

FIG. 8 illustrates software components within an example embodiment fora computer-based control system utilized within centrifuge-basedadditive object manufacturing according to the present invention. Theprocessing system 800 comprises a set of controller modules that performvarious functions of the operation of the 3D object manufacturing system100. These processing modules include a 3D module coordinate processor801, remote computer interface 802, a user/operator interface 803, asequence controller 811, an LSM vertical and radial position controller812, an LSM emitter timing coordinator 813, a rotating drum speedcontroller 814, a material insertion module 815, and a platform positioncontroller 816.

These controllers are electrically coupled to various motor driversbeing used within the 3D object manufacturing system 100. Thesecontrollers are also electrically connected to various sensors thatprovide position, speed, pressure, and all other control values usedwithin the 3D object manufacturing system 100 to read all the sensors,rotate drum 101, and provide all the linear motions commands as well asmodulating emitters in the light source module 103 and/or sending imagesto a light projecting unit in case of pressurized chamber.

The 3D module coordinate processor 801 includes a Job File Generator iscreated to convert a 3D representation of the model(s) that need to beprinted into the set of instructions for the various mechanisms of theprinter (emitters, projector, motors, nozzles etc.) to be performedsequentially in order to produce a printed model. These variousinstructions are sent to the sequence controller 811 for submission tothe individual function modules 812-816.

The remote computer interface 802 provides a communications channel toone or more computing systems to receive a 3D representation of themodels that need to be printed. The most common 3D file format in 3Dprinting is an STL format, where the entire model is represented as atriangular mash. However, many other file formats for 3D models existand may be used. These 3D representation of the models are typicallygenerated in other computing systems and transferred to the 3D objectmanufacturing system 100 for printing. These communications channels mayinclude wireless and wired networking connections such as Wi-Fi,cellular 3G LTE, 5G and the like, wired ethernet, fiber optic networks,and any similar communications channel. These channels may also includedirect computer to computer connections such as USB, serial connections,Bluetooth connections, and similar mechanisms to exchange data betweentwo connection computers.

The user/operator interface 803 includes a graphical user interface(GUI) to assist the operator to make an initial setup, load job files.start and stop the printing process, and all related command and controloperations needed by the 3D object manufacturing system 100. Theuser/operator interface 803 also permits the initiation of data transferand 3D model specifications to be downloaded from remote sources. Theuser/operator may receive data from the system 100 via a computerdisplay 804 and provide inputs using a keyboard 805 or similar device.The display 804 and keyboard 805 may be combined into a touch screendevice in various embodiments.

The sequence controller 811 receives the set of instructions for thevarious mechanisms of the printer (i.e. emitters, projector, motors,nozzles etc.) to be performed sequentially in order to produce a printedmodel. The sequence controller 811 passes the appropriate instructionsto each of to the individual function modules 812-816. When the printingof the 3D model is occurring, the sequence controller 811 providestiming and coordinating instructions to the to the individual functionmodules 812-816 in the proper order to perform the tasks for each stepin the printing process.

The LSM vertical and radial position controller 812 measures andmanipulates the position of the light source module 103 as needed duringeach step in the printing process. For each iteration of a printingoperation as described above with reference to the various disclosedembodiments, the light source module 103 provides light onto variousparts of a product made 109 to solidify material 105 into the 3d object.In order to illuminate material 105 at desired locations and not atother locations, the light source module 103 is moved to variouspositions to align its emitters with the locations to be solidified. TheLSM vertical and radial position controller 812 receives instructionsfrom the sequence controller 811, maintains a current position of thelight source module 103, and instructs the light source module 103 tomove to various locations as needed. Once performed, the LSM verticaland radial position controller 812 receives a command for the nextiteration and the process repeats until the product made 109 iscomplete.

The LSM emitter timing coordinator 813 activates the emitters within thelight source module 103 when they are directed at a desired location.For embodiments using a rotating drum 103, the LSM emitter timingcoordinator 813 obtains rotating drum speed from rotating drum speedcontroller 814 as well as its rotational position (which is typicallyspecified when the rotating drum 101 as a designated point on itscircumference passes a fixed spatial coordinate that that is passed onceevery revolution of the drum). With this data, the LSM emitter timingcoordinator 813 may determine when in the time of a rotation of the drumemitters are to be activated to illuminate desired locations. The LSMemitter timing coordinator 813 receives instructions from the sequencecontroller 811, maintains a current position of the light source module103, and instructs the light source module 103 activate its emitters asneeded. Once performed, the LSM emitter timing coordinator 813 receivesa command for the next iteration and the process repeats until theproduct made 109 is complete.

The rotating drum speed controller 814 commands a motor that spins therotating drum 103 to move in the various steps of the 3D printingoperations disclosed herein. The rotating drum speed controller 814actively maintains a measurement of the current rotational speed of therotating drum for used in determining is position as it rotates. Therotating drum speed controller 814 receives instructions from thesequence controller 811, maintains a rotational speed of the rotatingdrum 101, and instructs its motor to change speed as needed as needed.Once performed, the rotating drum speed controller 814 receives acommand for the next iteration and the process repeats until the productmade 109 is complete.

The material insertion module 815 receives instructions from thesequence controller 811, maintains the material 105 in the chamber at adesired level, and instructs its system to add or more remove material105. The material insertion module 815 controls the material insertionnozzles and/or the pressure level within a closed chamber to control thelevel of the material 105 as needed. Once performed, the materialinsertion module 815 receives a command for the next iteration and theprocess repeats until the product made 109 is complete.

The platform position controller 816 controls the position of a platformwithin the pressurized chamber or a rotating drum 101 that raises andlowers the product made 109 throughout the entire printing process. Theplatform position controller 816 may also raise a completed 3d objectout of the chamber when completed. The platform position controller 816controls the height or position of a base platform within a closedchamber to control the level of the product made 109 as needed. Onceperformed, the platform position controller 816 receives a command forthe next iteration and the process repeats until the product made 109 iscomplete.

FIG. 9 illustrates a generalized schematic of a programmable processingsystem utilized as the various computing components described hereinused to implement an embodiment of the present invention.

The central processing unit (“CPU”) 202 is coupled to the system bus204. The CPU 202 may be a general-purpose CPU or microprocessor,graphics processing unit (“GPU”), and/or microcontroller. The presentembodiments are not restricted by the architecture of the CPU 202 solong as the CPU 202, whether directly or indirectly, supports theoperations as described herein. The CPU 202 may execute the variouslogical instructions according to the present embodiments.

The computer system 200 also may include random access memory (RAM) 208,which may be synchronous RAM (SRAM), dynamic RAM (DRAM), synchronousdynamic RAM (SDRAM), or the like. The computer system 200 may utilizeRAM 208 to store the various data structures used by a softwareapplication. The computer system 200 also may include read only memory(ROM) 206 which may be PROM, EPROM, EEPROM, optical storage, or thelike. The ROM may store configuration information for booting thecomputer system 200. The RAM 208 and the ROM 206 hold user and systemdata, and both the RAM 208 and the ROM 206 may be randomly accessed.

The computer system 200 also may include an input/output (I/O) adapter210, a communications adapter 214, a user interface adapter 216, and adisplay adapter 222. The I/O adapter 210 and/or the user interfaceadapter 216 may, in certain embodiments, enable a user to interact withthe computer system 200. In a further embodiment, the display adapter222 may display a graphical user interface (GUI) associated with asoftware or web-based application on a display device 224, such as amonitor or touch screen.

The I/O adapter 210 may couple one or more storage devices 212, such asone or more of a hard drive, a solid-state storage device, a flashdrive, a compact disc (CD) drive, a floppy disk drive, and a tape drive,to the computer system 200. According to one embodiment, the datastorage 212 may be a separate server coupled to the computer system 200through a network connection to the I/O adapter 210. The communicationsadapter 214 may be adapted to couple the computer system 200 to thenetwork 208, which may be one or more of a LAN, WAN, and/or theInternet. The communications adapter 214 may also be adapted to couplethe computer system 200 to other networks such as a global positioningsystem (GPS) or a Bluetooth network. The user interface adapter 216couples user input devices, such as a keyboard 220, a pointing device218, and/or a touch screen (not shown) to the computer system 200. Thekeyboard 220 may be an on-screen keyboard displayed on a touch panel.Additional devices (not shown) such as a camera, microphone, videocamera, accelerometer, compass, and or gyroscope may be coupled to theuser interface adapter 216. The display adapter 222 may be driven by theCPU 202 to control the display on the display device 224. Any of thedevices 202-222 may be physical and/or logical.

The applications of the present disclosure are not limited to thearchitecture of computer system 200. Rather the computer system 200 isprovided as an example of one type of computing device that may beadapted to perform the functions of the centrifuge-based additive objectmanufacturing as shown in FIG. 3. For example, any suitableprocessor-based device may be utilized including, without limitation,personal data assistants (PDAs), tablet computers, smartphones, computergame consoles, and multi-processor servers. Moreover, the systems andmethods of the present disclosure may be implemented on applicationspecific integrated circuits (ASIC), very large scale integrated (VLSI)circuits, or other circuitry. In fact, persons of ordinary skill in theart may utilize any number of suitable structures capable of executinglogical operations according to the described embodiments. For example,the computer system 200 may be virtualized for access by multiple usersand/or applications.

Additionally, the embodiments described herein are implemented aslogical operations performed by a computer. The logical operations ofthese various embodiments of the present invention are implemented (1)as a sequence of computer implemented steps or program modules runningon a computing system and/or (2) as interconnected machine modules orhardware logic within the computing system. The implementation is amatter of choice dependent on the performance requirements of thecomputing system implementing the invention. Accordingly, the logicaloperations making up the embodiments of the invention described hereincan be variously referred to as operations, steps, or modules.

Since other modifications and changes varied to fit particular operatingrequirements and environments will be apparent to those skilled in theart, the invention is not considered limited to the example chosen forpurposes of disclosure, and covers all changes and modifications whichdo not constitute departures from the true spirit and scope of thisinvention. This written description provides an illustrative explanationand/or account of the present invention. It may be possible to deliverequivalent benefits using variations of the specific embodiments,without departing from the inventive concept. This description and thesedrawings, therefore, are to be regarded as illustrative and notrestrictive.

Unless otherwise indicated, all numbers expressing quantities ofingredients, properties such as molecular weight, percent, ratio,reaction conditions, and so forth used in the specification and claimsare to be understood as being modified in all instances by the term“about,” whether or not the term “about” is present. Accordingly, unlessindicated to the contrary, the numerical parameters set forth in thespecification and claims are approximations that may vary depending uponthe desired properties sought to be obtained by the present disclosure.At the very least, and not as an attempt to limit the application of thedoctrine of equivalents to the scope of the claims, each numericalparameter should at least be construed in light of the number ofreported significant digits and by applying ordinary roundingtechniques. Notwithstanding that the numerical ranges and parameterssetting forth the broad scope of the disclosure are approximations, thenumerical values set forth in the specific examples are reported asprecisely as possible. Any numerical value, however, inherently containscertain errors necessarily resulting from the standard deviation foundin the testing measurements.

It will be further understood that various changes in the details,materials, and arrangements of the parts which have been described andillustrated in order to explain embodiments of this invention may bemade by those skilled in the art without departing from embodiments ofthe invention encompassed by the following claims.

In this specification including any claims, the term “each” may be usedto refer to one or more specified characteristics of a plurality ofpreviously recited elements or steps. When used with the open-ended term“comprising,” the recitation of the term “each” does not excludeadditional, unrecited elements or steps. Thus, it will be understoodthat an apparatus may have additional, unrecited elements and a methodmay have additional, unrecited steps, where the additional, unrecitedelements or steps do not have the one or more specified characteristics.

What is claimed is:
 1. A system for providing centrifuge-based additiveobject manufacturing, the system comprising: a rotating drum containinga photopolymer material that solidifies when irradiated by a lightsource, the photopolymer material spreads evenly over an item beingmanufactured when the rotating drum is in motion; a light source moduleemitting a light capable of solidifying the photopolymer material; a setof platform actuator elements coupled to a plurality of perforatedplatforms for controlling a position of the plurality of perforatedplatforms within the rotating drum while in operation; and aphotopolymer material delivery system for adding a controlled amount ofthe photopolymer material into the rotating drum; wherein the lightsource module moves inside the rotating drum and selectively emits itslight solidifying the part of the layer above the plurality ofperforated platforms in the areas crossing the object currently beingmanufactured.
 2. The system according to claim 1, wherein thephotopolymer material delivery system adds additional photopolymermaterial to the rotating drum after the light source module solidifies anew layer onto the item being manufactured before the light sourcemodule activates to solidify a next layer.
 3. The system according toclaim 2, wherein air pressure within the rotating drum is raised abovesurrounding atmospheric air pressure while the rotating drum is inoperation.
 4. The system according to claim 2, wherein centrifugal forceexerted onto the photopolymer material within the rotating drum israised above surrounding gravity while the rotating drum is inoperation.
 5. The system according to claim 1, wherein the photopolymermaterial delivery system comprises a material delivery module insertedwithin the rotating drum on an opposing side from the light sourcemodule.
 6. The system according to claim 1, wherein the photopolymermaterial delivery system comprises a set of material delivery nozzleslocated on a bottom surface within the rotating drum on an opposing sidefrom the light source module.
 7. A system for providing pressure-basedadditive object manufacturing, the system comprising: a pressure vesselcontaining a photopolymer material that solidifies when irradiated by alight source, the photopolymer material spreads evenly over an itembeing manufactured when the rotating drum is in motion, the pressurevessel having a transparent top surface; a light source module emittinga light capable of solidifying a top layer of the photopolymer materialthrough the transparent top surface of the pressure vessel; a platformactuator coupled to a movable platform for controlling a verticalposition of the movable platform within the pressure vessel while inoperation, the platform actuator moves to position a current top surfacethe item being manufactured a single layer below a current level of thephotopolymer material; and a photopolymer material delivery system foradding a controlled amount of the photopolymer material into thepressure vessel; wherein the light source module selectively emits itslight solidifying the single layer below a current level of thephotopolymer material above the object currently being manufactured. 8.The system according to claim 7, wherein the light source module emits adifferent light pattern for each layer of the item being manufactured tosolidify the photopolymer material according to the different lightpattern.
 9. The system according to claim 8, wherein the system furthercomprises a photopolymer material delivery system for adding acontrolled amount of the photopolymer material into the pressure vessel.10. The system according to claim 7, wherein air pressure within thepressure vessel is raised above surrounding atmospheric air pressurewhile the pressure vessel is in operation.
 11. A method for providingcentrifuge-based additive object manufacturing, the method comprising:rotating a drum having set of platform actuator elements coupled to aplurality of perforated platforms for controlling a position of theplurality of perforated platforms within the rotating drum; inserting acontrolled amount of photopolymer material into the rotating drum;selectively solidifying a layer of the photopolymer material onto anitem being manufactured using a light source module emitting its lightonto the layer of the photopolymer material; and adjusting a position ofthe light source module to a new position to solidify a next layer ofthe photopolymer material.
 12. The method according to claim 11, whereinthe method further comprises adding additional photopolymer material tothe rotating drum before solidifying the next layer.
 13. The methodaccording to claim 11, wherein air pressure within the rotating drum israised above surrounding atmospheric air pressure while the rotatingdrum is in operation.
 14. The method according to claim 11, whereincentrifugal force exerted onto the photopolymer material within therotating drum is raised above surrounding gravity while the rotatingdrum is in operation.
 15. The method according to claim 12, whereinadding additional photopolymer material to the rotating drum utilizes aphotopolymer material delivery system comprises a material deliverymodule inserted within the rotating drum on an opposing side from thelight source module.
 16. The system according to claim 12, whereinadding additional photopolymer material to the rotating drum utilizes aphotopolymer material delivery system comprises a set of materialdelivery nozzles located on a bottom surface within the rotating drum onan opposing side from the light source module.